ABB Feather Duster V2 User manual

ROBOTICS
Product manual
Feather Duster V2

Trace back information:
Workspace Systems version a4
Checked in 2018-11-29
Skribenta version 5.3.012

Product manual
Feather Duster V2
Document ID: 3HAX010000210
Revision: A
© Copyright 2018 ABB. All rights reserved.
Specifications subject to change without notice.

The information in this manual is subject to change without notice and should not
be construed as a commitment by ABB. ABB assumes no responsibility for any errors
that may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Keep for future reference.
Additional copies of this manual may be obtained from ABB.
Original instructions.
© Copyright 2018 ABB. All rights reserved.
Specifications subject to change without notice.
ABB AB, Robotics
Robotics and Motion
Se-721 68 Västerås
Sweden

Table of contents
7Overview of this manual ...................................................................................................................
9Product documentation ....................................................................................................................
11How to read the product manual ......................................................................................................
131 Safety
131.1 General safety information ..................................................................................
131.1.1 Limitation of liability .................................................................................
151.1.2 Protective stop and emergency stop ...........................................................
161.2 Safety actions ...................................................................................................
161.2.1 Fire extinguishing ....................................................................................
171.2.2 Make sure that the main power has been switched off ....................................
181.3 Safety risks ......................................................................................................
181.3.1 Safety risks during installation and service work ...........................................
201.3.2 Moving equipment is potentially lethal .........................................................
211.3.3 First test run may cause injury or damage ....................................................
221.3.4 Work inside the working range of the Product ...............................................
231.3.5 Enabling device and hold-to-run functionality ...............................................
241.3.6 Risks associated with live electric parts .......................................................
261.3.7 Hot parts may cause burns .......................................................................
271.3.8 Brake testing ..........................................................................................
281.4 Safety signals and symbols .................................................................................
281.4.1 Safety signals in the manual ......................................................................
301.4.2 Safety symbols on product labels ...............................................................
352 About Feather Duster V2
352.1 Feather Duster V2 system ...................................................................................
352.1.1 Introduction ............................................................................................
382.1.2 Process diagram .....................................................................................
392.2 Main components ..............................................................................................
392.2.1 Component overview ...............................................................................
402.2.2 Feather roller ..........................................................................................
422.2.3 Ionization unit .........................................................................................
452.2.4 Exhaust system ......................................................................................
462.2.5 Compressed air system ............................................................................
473 Installation and commissioning
473.1 Introduction ......................................................................................................
483.2 Technical specification .......................................................................................
513.3 On-site installation ............................................................................................
513.3.1 Pre-installation procedure .........................................................................
533.3.2 Lifting Feather Duster V2 with lifting accessories ..........................................
573.3.3 Installing the Feather Duster V2 .................................................................
673.3.4 Connecting exhaust hose and cables ..........................................................
723.4 Electrical connection ..........................................................................................
753.5 System start-up ................................................................................................
794 Maintenance
794.1 Introduction ......................................................................................................
804.2 Maintenance schedule .......................................................................................
804.2.1 Specification of maintenance intervals ........................................................
814.2.2 Maintenance schedule .............................................................................
834.3 Cleaning activities .............................................................................................
834.3.1 Cleaning the Feather Duster V2 .................................................................
864.4 Inspection activities ...........................................................................................
864.4.1 Inspecting feathers .................................................................................
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Table of contents

874.4.2 Inspecting the ionization unit ....................................................................
894.4.3 Inspecting the cabling and exhaust hose ....................................................
914.4.4 Inspecting the timing belt .........................................................................
955 Repair
955.1 Introduction ......................................................................................................
965.2 Repairing activities ............................................................................................
965.2.1 Replacing the feather roller ......................................................................
1035.2.2 Replacing the cable chain .........................................................................
1195.2.3 Replacing the timing belt .........................................................................
1265.2.4 Replacing the bearing housing ..................................................................
1435.2.5 Replacing the ionization unit .....................................................................
1515.2.6 Replacing the safety edge sensor ..............................................................
1555.2.7 Replacing the motor ................................................................................
1696 Decommissioning
1696.1 Introduction ......................................................................................................
1706.2 Environmental information ..................................................................................
1716.3 Dismantle ........................................................................................................
1737 Reference information
1737.1 Introduction ......................................................................................................
1747.2 Unit conversion .................................................................................................
1757.3 Screw joints ....................................................................................................
1787.4 Standard toolkit ................................................................................................
1797.5 Special tools ....................................................................................................
1818 Spare parts
1818.1 Introduction ......................................................................................................
1828.2 Spare part list and illustration ..............................................................................
1879 Circuit diagrams
189Index
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Table of contents

Overview of this manual
About this manual
This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work and calibration.
Who should read this manual?
This manual is intended for:
• installation personnel
• maintenance personnel
• repair personnel.
Prerequisites
A maintenance/repair/installation craftsman working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters - NOT MANDATORY
The manual is organized in the following chapters:
ContentsChapter
References
Documentation of ABB products, referred to in the manual, is listed in the table
below.
Document IDDocument name of ABB products
3HAC047136-001Product manual - IRC5
3HAC031045-001Operating manual - General safety information i
3HAC027097-001Operating manual - Getting started, IRC5 and RobotStudio
3HAC050944-001Operating manual - Service Information System
3HAC050941-001Operating manual - IRC5 with FlexPendant
3HAC026876-001Product manual - IRB 6640
3HAC044266-001Product manual - IRB 6700
3HAC028284-001Product specification - IRB 6640
Continues on next page
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Overview of this manual

Document IDDocument name of ABB products
3HAC044265-001Product specification - IRB 6700
3HAC050992-001Application manual - DeviceNet Master/Slave
iThis manual contains all safety instructions from the product manuals for the manipulators and the
controllers.
Documentation of non-ABB products, be referred to while using the Feather Duster
V2, is listed in the table below.
Document
ID
Download from...Document name of non-ABB
products
http://dj.hstyq.com/Up-
load/down/80WD/80WD-M02410-
24V%20Model.pdf
Product Manual of Motor 80WD-
M02410-24V
https://www.slipring.cn/up-
Load/product/month_1710/201710181737252791.pdf
LPT080 Series Slip Ring with Through
Bore 80mm
https://www.keyence.com.cn/mykey-
ence/?ptn=001&dlLangType=en-
GB&dlLangId=
Ultra-High Speed, Sheath-Sensing
Ioniser, SJ-H Series
Revisions
DescriptionRevision
First edition.-
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Overview of this manual
Continued

Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics is divided into a number of categories.
This listing is based on the type of information in the documents, regardless of
whether the products are standard or optional.
All documents can be found via myABB Business Portal, www.myportal.abb.com.
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
•Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Technical reference manuals
The technical reference manuals describe reference information for robotics
products, for example lubrication, the RAPID language, and system parameters.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Continues on next page
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Product documentation

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
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Product documentation
Continued

How to read the product manual
Reading the procedures
The procedures contain all information required for the installation or service activity
and can be printed out separately when needed for a certain service procedure.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 13.
Illustrations
The manipulator is illustrated with general figures that does not take painting or
protection type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
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How to read the product manual

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1 Safety
1.1 General safety information
1.1.1 Limitation of liability
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the Feather Duster V2 (hereinafter, the Product) will not cause
injury or damage even if all safety instructions are complied with.
The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system.
In particular, liability cannot be accepted if injury/damage has been caused for any
of the following reasons:
• Use of the Product in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the Product when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications made in or around the Product.
• Repairs carried out by in-experienced or non-qualified personnel.
• Foreign objects.
• Force majeure.
Nation/region specific regulations
To protect personnel, the complete system must be designed and installed in
accordance with the safety requirements set forth in the standards and regulations
of the country where the Product is installed.
To be observed by the supplier of the complete system
The integrator is responsible that the safety devices necessary to protect people
working with the Product are designed and installed correctly.
When integrating the Product with external devices and machines:
• The supplier of the complete system must ensure that all circuits used in the
safety function are interlocked in accordance with the applicable standards
for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance
with the applicable standards for the emergency stop function.
Continues on next page
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1 Safety
1.1.1 Limitation of liability

The integrator of the final application is required to perform an assessment of the
hazards and risks (HRA).
Note
The integrator is responsible for the safety of the final application.
Safe access
The Product shall be designed to allow safe access to all areas where intervention
is necessary during operation, adjustment, and maintenance.
Where it is necessary to perform tasks within the safeguarded space there shall
be safe and adequate access to the task locations.
Safety zones, which must be crossed before admittance, must be set up in front
of the Product's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the Product's
working space.
A safety fence is recommended to ensure safeguarded space. Sufficient space
must be provided around the Product to protect those working with or on it from
hazards such as crushing.
The fence or enclosure must be dimensioned to withstand the force created if the
load being handled by the Product is dropped or released at maximum speed.
Also consider the maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the Product.
Safe handling
Users shall not be exposed to hazards, including slipping, tripping, and falling
hazards.
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure
that guards remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Emergency stop buttons must be positioned in easily accessible places so that
the Product can be stopped quickly. If any of the buttons do not stop all the product
workcell motion, each emergency stop button must be marked, if more than one
is provided, to indicate its designated safety function.
Grippers/end effectors must be designed so that they retain work pieces in the
event of a power failure or a disturbance to the controller.
Unauthorized modifications of the originally delivered product/system are prohibited.
Without the consent of ABB it is forbidden to attach additional parts through welding,
riveting, or drilling of new holes into the castings. The strength could be affected.
CAUTION
Ensure that a gripper is prevented from dropping a work piece, if such is used.
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1 Safety
1.1.1 Limitation of liability
Continued

1.1.2 Protective stop and emergency stop
Overview
The protective stops and emergency stops are described in the product manual
for the controller.
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1 Safety
1.1.2 Protective stop and emergency stop

1.2 Safety actions
1.2.1 Fire extinguishing
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the Product
or controller.
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1 Safety
1.2.1 Fire extinguishing

1.2.2 Make sure that the main power has been switched off
Description
Working with high voltage is potentially lethal. Persons subjected to high voltage
may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these
personal injuries, switch off the main power on the controller before proceeding
work.
Note
Switch off all main power switches in a MultiMove system.
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1 Safety
1.2.2 Make sure that the main power has been switched off

1.3 Safety risks
1.3.1 Safety risks during installation and service work
Requirements on personnel
Only persons who know the Product and are trained in the operation and handling
of the Product are allowed to maintain the Product. Persons who are under the
influence of alcohol, drugs or any other intoxicating substances are not allowed
to install, maintain, repair, or use the Product.
• Those in charge of operations must make sure that safety instructions are
available for the installation in question.
• Those who install or service/maintain the Product must have the appropriate
training for the equipment in question and in any safety matters associated
with it.
• Personnel should be trained on responding to emergency or abnormal
situations.
General risks during installation and service
The instructions in the product manual must always be followed.
• Never turn the power on to the Product before it is properly fixed and bolted
to its foundation/support.
• Make sure that no one else can turn on the power to the controller and
Product while you are working with the system. A good method is to always
lock the main switch on the controller cabinet with a safety lock.
• Make sure that no one else can turn on the power to the controller and
Product while you are working with the system. A good method is to remove
the power cable to the controller.
• If the Product is installed at a height, hanging, or other than standing directly
on the floor, there may be additional risks than those for a Product standing
directly on the floor.
• Energy stored in the Product for the purpose of counterbalancing certain
axes may be released if the Product, or parts thereof, are dismantled.
• Never use the Product as a ladder, which means, do not climb on the
controller, motors, or other parts during service work. There is a risk of
slipping because of the high temperature of the motors and oil spills that can
occur on the Product. There is also a risk of the Product being damaged.
• To avoid damaging the Product, make sure that there are no loose screws,
turnings, or other parts inside the Product after work has been performed.
Safety risks during operational disturbances
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Continues on next page
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1 Safety
1.3.1 Safety risks during installation and service work

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.
Spare parts and special equipment
ABB does not supply spare parts and special equipment which have not been
tested and approved by ABB. The installation and/or use of such equipment could
negatively affect the structural properties of the Product and as a result of that
affect the active or passive safety operation. ABB is not liable for damages caused
by the use of non-original spare parts and special equipment. ABB is not liable for
damages or injuries caused by unauthorized modifications to the Product.
Personal protective equipment
Always use suitable personal protective equipment, based on the risk assessment
for the Product installation.
Allergenic material
See Environmental information on page 170 for specification of allergenic materials
in the Product, if any.
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1 Safety
1.3.1 Safety risks during installation and service work
Continued

1.3.2 Moving equipment is potentially lethal
Description
Any moving equipment is a potentially lethal machine.
When running, the Product may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may
seriously injure any personnel and/or damage any piece of equipment located
within the working range of the Product.
Safe handling
NoteAction
Emergency stop equipment such as gates,
tread mats, light curtains, etc.
Before attempting to run the Product, make
sure all emergency stop equipment is cor-
rectly installed and connected.
1
How to use the hold-to-run function is de-
scribed in section How to use the hold-to-
run function in the Operating manual - IRC5
with FlexPendant.
Usually the hold-to-run function is active
only in manual full speed mode. To in-
crease safety it is also possible to activate
hold-to-run for manual reduced speed with
a system parameter.
2
The hold-to-run function is used in manual
mode, not in automatic mode.
Make sure no personnel are present within
the working range of the Product before
pressing the start button.
3
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1 Safety
1.3.2 Moving equipment is potentially lethal